Overhead and Gantry Crane Safety Procedures

Overhead and Gantry Crane Procedure Approval Date: 3/9/11 Effective Date: 3/9/11
Safety & Health Manual
INTERNATIONAL PAPER Franklin, VA Page 1 of 11
Overhead and Gantry Crane Procedure

1.0 PURPOSE The purpose of this procedure is to outline the requirements for working on and around overhead and gantry cranes.
2.0
SCOPE These procedures apply to any International Paper employee or contractor working on, near, or from an overhead or gantry crane (house, bridge, or reel).
3.0
DEFINITIONS 3.1 Working On - Activities required to maintain cranes in an operational condition. These activities include troubleshooting controls, replacing cables, maintenance and required inspections. Such activity frequently requires one or more employees to access the crane with the power source to the crane energized and may require the crane to be moved while personnel are on the crane. Working Near - Activities required in the vicinity of a crane, where movement of the crane could pose a hazard to the employees performing the activity. These activities include crane rail repairs, reel crane repairs, etc. Working From - Activities where the overhead and gantry crane is used as an access platform. These activities include inspection of crane power rails, ceiling lighting maintenance, fire sprinkler system maintenance, work on paper machine hoods, etc. Frequently the crane must be moved as part of this activity while personnel are on the crane. Overhead Crane - crane with a movable bridge carrying a movable or fixed hoisting mechanism and traveling on an overhead, fixed runway structure (i.e. house crane). Gantry Crane - a crane similar to an overhead crane, except that the bridge for carrying the trolley (or trolleys) is rigidly supported on two or more legs running on fixed rails or other runway (i.e. reel crane). Main Disconnect - switch controlling the entire power supply to the crane (operating floor or substation).
3.2
3.3
3.4
3.5
3.6
WARNING: Do not use this document after end of shift March 5, 2012
3.7
Master Switch - switch which dominates the operation of contactors, relays, or other remotely operated devices (on the crane). Work Area: Area around the idle crane that is established by the crane crew. It indicates a boundary for adjacent crane operators. Entry into the work area by adjacent cranes is by permission from the Pendant Attendant Lookout. Barriers (cones and signage) shall mark the work area boundaries. Crane Lockout person - employee assigned the task of locking out or deenergizing the power supply (main switch) to a crane as employees are accessing or egressing the crane. Pendant Attendant / Lookout - employee assigned to maintain exclusive control of the operational control pendant for the crane being worked on or identify potential hazards to employees working on, near or from cranes and provide warning to these employees. 3.10.1 Located full time at a visual vantage point for observing the approach of an adjacent crane or cranes. 3.10.2 Shall prohibit contact by the active crane(s) with the idle crane, with persons performing maintenance, and with equipment used in performing the maintenance. 3.10.3 Maintains marker and signage used to establish Work Area. 3.10.4 Effectively maintains radio and visual contact with the personnel performing maintenance or other activities on or near the travel path of the crane. 3.10.5 An orange safety vest shall be worn to identify the Pendant Attendant / Lookout. 3.10.6 Know the location of house crane disconnects and how to properly operate them. 3.10.7 Know where closest working phone is located to summon help in case of an emergency. 3.10.8 Monitors safety and well-being of crane crews. 3.10.9 Shall be CPR trained if work on, near, or from an overhead or gantry crane will involve working on energized electrical circuits.
3.8
3.9
3.10
3.11
Crane Rail Stop - device used to limit the travel of a crane bridge. This device is attached to a fixed structure.
4.0
WORKING ON OVERHEAD AND GANTRY CRANES This procedure is to be followed while working on (i.e. repairs, preventive maintenance, etc.) overhead and gantry cranes. 4.1 If the crane to be worked on will operate, it shall be run to a location where it will cause the least amount of interference with other cranes and operations in the area. When work being performed on the crane presents a working overhead hazard appropriate warning signs and barriers shall be utilized on the floor beneath the crane. Personnel working on the crane must utilize all required personal protective equipment including a harness and lanyard unless the use of these creates a more hazardous situation. If the crane is constructed with a work platform with fixed fall protection, a harness and lanyard are not required; however any work where there is no fixed fall protection will require the use of this equipment. The preferred method for working on the crane is to have the crane power source de-energized and locked out at the main switch by each individual (personal lockout) working on crane. In some cases there are multiple cranes on the same runway. Each crane is powered from a common power source (bus), which if deenergized would render each crane inoperable. If the bus cannot be de-energized or when working on any reel crane special steps must be taken to prevent operations of any nearby crane that could pose a hazard to employees working on an adjacent crane. The following procedure will be utilized whenever a crane has to remain energized. 4.5.1 A pre-job discussion (Tool Box meeting) of the safety procedures and the work plan will be conducted with all personnel assigned to the task. A Pendant Attendant / Lookout will be stationed at the crane control pendant to limit operations to only those requested and authorized by the personnel working on the crane. This person will have no other job assignment which is unrelated to the work on the crane (i.e. winder operator, etc.). Line of sight contact between the Pendant Attendant / Lookout and the personnel working on the crane is required. This may require an intermediate person (lookout) to relay signals and maintain line of sight
4.2
4.3
4.4
4.5
4.5.2
4.5.3
contact with those working on the crane. Radio communication must be provided to the pendant attendant / lookout, and a member of the work crew. An alternate system of communication maybe utilized if radios are not available or will not work due to dead radio areas (See item 4.5.6 in this section for details). 4.5.4 Caution Tags shall be placed on the control pendants of all other cranes operating in the area to alert potential users that personnel are performing a task on a nearby crane and could be jeopardized by movement of the crane on which the Caution Tag is attached. Where other cranes are in operation on the same runway, approved rail stops or one of the following means shall be used to prevent interference or contact with the crane being worked on. 4.5.5.1 4.5.5.2 Lockout master switch (secondary disconnects) of other cranes. Provide a Lookout (signal person) located full time at a visual vantage point for observing the approach and prohibiting contact with the idle crane.
4.5.5
When rail stops are employed, they should be designed to contact something other than the wheels of the crane (i.e. frame) and if they must contact the wheel the stop height must be equal to or greater than the radius of the wheel. 4.5.6 When personnel are accessing or egressing the crane, the Pendant Attendant / Lookout will be station at the pendant to maintain exclusive control of the crane until the employee(s) are completely on or off the crane. Once on the crane, the employee(s) working on the crane will lockout the secondary disconnect on the crane bridge with a personal lock. Personnel accessing the crane must be fully aware of the location of the crane power bus and the fact that it will be energized while they are on the crane.
4.5.7
4.5.8
4.6
In circumstances where cranes operate on adjacent parallel runways the cranes will be de-energized during access/egress. If the adjacent crane can be deenergized, each employee working on the idle crane will place a personal lock on the main disconnect of the adjacent crane. If the adjacent crane must be left energized: 4.6.1 Follow all procedures in Section 4.5.
4.6.2
Install a guard or barrier the length of the work area on the crane runway to prevent contact between crewmembers on the idle crane and the active adjacent crane.
4.7
Special Requirements 4.7.1 4.7.2 At times the crane maybe traveling with personnel on the bridge. In these circumstances the procedure outlined in Section 6.3 must be followed. If the Overhead crane has to be used to remove equipment from a reel crane, requirements under Section 6.3 will be followed.
5.0
WORKING NEAR OVERHEAD AND GANTRY CRANES 5.1 The preferred method for working in the vicinity of or within eight feet of the lowest point of the overhead and gantry cranes is for individuals performing the work to de-energize the power source at the main switch utilizing the Lock, Tag and Try procedure. If the work is such that cranes in the vicinity must remain in operation the following precautions must be taken: 5.2.1 A pre-job discussion (Tool Box meeting) of safety procedures and the work plan must be conducted and include all personnel involved in the work. Provide a dedicated Pendant Attendant/Lookout who will watch for crane movements that might create a hazard to those performing the work. Caution Tags on all operational crane control pendants to alert potential users that someone is performing a task in the vicinity and could be jeopardized by movement of the crane on which the Caution Tag is attached. In addition, provide verbal notification to other personnel in the area who may use the cranes that work is in progress in the vicinity. Place approved rail stops on the crane rails a minimum of 15 feet in each direction from the site of the work or provide a Lockout person who will remain in radio contact with the Lookout. The Lockout person will be stationed at the Main Switch and de-energize the system if a problem is identified by the Lookout.
5.2
5.2.2
5.2.3
5.2.4
6.0
WORKING FROM OVERHEAD AND GANTRY CRANES 6.1 Personnel accessing the crane must utilize all required and appropriate personal protective equipment (including fall protection). If it is possible to access the crane safely at the location for the work to be performed, the following precautions must be taken: 6.2.1 A pre-job discussion (Tool Box meeting) of safety procedures and the work plan must be conducted and include all personnel involved in the work. Move the crane to the desired location. De-energize the crane, each employee working from the crane will lockout the main or master switch following the Lock, Tag and Try procedure unless otherwise noted in item Section 6.3. A Caution Tag will be attached to the pendant of all cranes in the vicinity which remain operational while the work is being performed to alert potential users that someone is working from a nearby crane and could be jeopardized by movement of the crane on which the Caution Tag is attached.
6.2
6.2.2 6.2.3
6.2.4
6.2.5
If cranes are operational on the same runway, approved rail stops or other means as outlined in Section 4.5.5 will be utilized to prevent interference or contact with the crane being used as a work platform. The area under the crane must be barricaded to prevent other personnel from entering the area.
6.2.6
6.3
If the crane cannot be safely accessed at the location of the work to be performed, or if movement of the crane with personnel on the crane is to occur, the following precautions must be taken: 6.3.1 A pre-job review discussion (Tool Box meeting) of safety procedures and work plan must be done by all personnel involved. A pendant Attendant / Lookout will be stationed at the crane control pendant to limit crane operations only to those required and authorized by the personnel working from the crane. Line of sight contact between the Pendant Attendant / Lookout and the personnel working from the crane is required. This may require an intermediate person
6.3.2
6.3.3
(Lookout) to relay signals and maintain line of sight contact. Radio Communication must be provided to the Pendant Attendant / Lookout, and a member of the work crew. An alternate system of communication maybe utilized if radios are not available or will not work due to dead radio areas (See item 6.3.6 in this section for details). 6.3.4 Caution Tags shall be placed on the crane control pendants of all other cranes operating in the area to alert potential users that someone is working from a nearby crane and could be jeopardized by movement of the crane where the Caution Tag is located. Where other cranes are in operation on the same runway, apply approved rail stops or provide a Lookout (signal person) located full time at a visual vantage point for observing the approach of the other crane and prohibiting contact with the idle crane. When rail stops are employed, they should be designed to contact something other than the wheels of the crane (i.e. frame) and if they must contact the wheel, the stop height must be equal to or greater than the radius of the wheel. 6.3.6 When personnel are accessing or egressing the crane, the Pendant Attendant / Lookout will be station at the pendant to maintain exclusive control of the crane until the employee(s) are completely on or off the crane. Personnel accessing the crane must be fully aware of the location of the crane power bus and the fact that it will be energized while they are on the crane. While the crane is in motion any employee on the crane shall be seated or kneeling on the walkway such that they are lower than the platform handrail. Areas on the floor below the crane where work is being performed must be barricaded with barricade tape to prevent other personnel from entering the area and distracting the Pendant Attendant / Lookout.
6.3.5
6.3.7
6.3.8
6.3.9
7.0
TRAINING REQUIREMENTS All employees who work on, near or from overhead and gantry cranes shall be trained in the details of this procedure upon initial assignment and every 2 years thereafter. Training is required for each distinctly different type of crane that may be utilized by the employee. The training will include at a minimum: 7.1 7.2 The elements of these procedures. The operation of each distinctly different crane.
7.3 7.4
Pre-use checks required prior to operating a crane. The specific duties for: 7.4.1 7.4.2 7.4.3 Pendant Attendant / Lookout. Crane Lookout person (maintains line of sight). Dedicated Lockout person (5.2.4)
7.5 7.6 8.0
Approved hand signals for overhead cranes. Written test of comprehension
APPROVAL AND ISSUE This procedure is approved by the Franklin Lead Team.
9.0
REVISION HISTORY DATE Mar 1, 2011 MODIFICATIONS New
Working on the crane while de-energized Repair of the crane and PMs A pre-job discussion (Tool Box meeting). Personnel working on the crane must utilize all required personal protective equipment including a harness and lanyard unless the use of these creates a more hazardous situation. If the crane to be worked on will operate, can it be run to a location where it will cause the least amount of interference with other cranes and operations in the area. If a load is attached to the crane, it shall be landed (if possible). Where other cranes are in operation on the same runway, lockout master switch (secondary disconnects) of other cranes. Approved barriers shall be used to prevent interference or contact with crane being worked on. Warning signs and barriers shall be utilized on the floor beneath the crane. Caution Tags shall be placed on the control pendants of all other cranes operating in the area. Place crane in ZES by each individual locking the main switch or Group Lock Box. Provide a dedicated Attendant / Lookout who will watch for crane movements that might create a hazard to those performing the work. An orange vest shall be worn to identify this person as attendant / lookout.
Working on the crane while energized. Repair of the crane and PMs A pre-job discussion (Tool Box meeting). Personnel working on the crane must utilize all required personal protective equipment including a harness and lanyard unless the use of these creates a more hazardous situation. If the crane to be worked on will operate, can it be run to a location where it will cause the least amount of interference with other cranes and operations in the area. If a load is attached to the crane, it shall be landed (if possible). Where other cranes are in operation on the same runway, lockout master switch (secondary disconnects) of other cranes. Approved barriers shall be used to prevent interference or contact with crane being worked on. Warning signs and barriers shall be utilized on the floor beneath the crane. Caution Tags shall be placed on the control pendants of all other cranes operating in the area. Personnel accessing the crane must be fully aware of the location of the crane power bus and the fact that it will be energized while they are on the crane. When personnel are accessing or egressing the crane, the Pendant Attendant will be station at the pendant to maintain exclusive control of the crane until the employee(s) are completely on or off the crane. An orange vest shall be worn to identify this person as attendant / lookout.
Working in the vicinity of or within eight feet of Working in the vicinity of or within eight feet of the lowest point of the crane bridge and the the lowest point of the crane bridge and the crane(s) can be de-energized. crane(s) is energized. Employees performing work on paper machines, Employees performing work on paper machines, building and other equipment building and other equipment A pre-job discussion (Tool Box meeting) of safety procedures and the work plan must be conducted and include all personnel involved in the work. A pre-job discussion (Tool Box meeting) of safety procedures and the work plan must be conducted and include all personnel involved in the work.
Place crane(s) in ZES by each individual locking the A Pendant Attendant / Lookout will be stationed on main switch or Group Lock Box. the floor and must have line of sight contact with employees working on the job. Attendant will watch for crane movements that might create a hazard to those performing the work. An orange vest shall be worn to identify this person as attendant / lookout. Warning signs and barriers shall be utilized on the floor. Caution Tags on all operational crane control pendants to alert potential users that someone is performing a task in the vicinity. Provide a dedicated Pendant Attendant who will watch for crane movements that might create a hazard to those performing the work. An orange vest shall be worn to identify this person as attendant / lookout. Warning signs and barriers shall be utilized on the floor. Caution Tags shall be placed on the control pendants of all other cranes operating in the area to alert potential users that someone is performing a task in the vicinity.
Working from the crane and the crane(s) can be Working from the crane and the crane(s) is de-energized. energized. Employees performing work while utilizing the crane as a work platform. A pre-job discussion (Tool Box meeting) of safety procedures and the work plan must be conducted and include all personnel involved in the work. Personnel working on the crane must utilize all required personal protective equipment including a harness and lanyard Move crane into position needed to complete the work before individual(s) access crane. Place crane in ZES by each individual locking the main switch or Group Lock Box. Employees performing work while utilizing the crane as a work platform. A pre-job discussion (Tool Box meeting) of safety procedures and the work plan must be conducted and include all personnel involved in the work. Personnel working on the crane must utilize all required personal protective equipment including a harness and lanyard. When personnel are accessing or egressing the crane, the Pendant Attendant will be stationed at the pendant to maintain exclusive control of the crane until the employee(s) are completely on or off the crane. An orange vest shall be worn to identify this person as attendant / lookout. Provide a dedicated Attendant / Lookout who will watch for crane movements that might create a hazard to those performing the work. An orange vest shall be worn to identify this person as attendant / lookout. Move crane so personnel can access the crane, once on the crane personnel will utilize fall protection while on crane performing work
Warning signs and barriers shall be utilized on the floor beneath the crane.
Provide a dedicated Attendant / Lookout who will watch for crane movements that might create a hazard to those performing the work. An orange vest shall be worn to identify this person as attendant / lookout. Caution Tags shall be placed on the control pendants of all other cranes operating in the area.
Personnel on the crane will pull the pendant up to the bridge so the crane operations will be controlled by personnel on the crane. While the crane is in motion any employee on the crane shall be seated or kneeling on the walkway such that they are lower than the platform handrail. Warning signs and barriers shall be utilized on the floor beneath the crane.

Overhead and Gantry Crane Safety Procedures

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Overhead and Gantry Crane Safety Procedures

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Overhead and Gantry Crane Procedure Approval Date: 3/9/11 Effective Date: 3/9/11

Safety & Health Manual

INTERNATIONAL PAPER Franklin, VA Page 1 of 11

Overhead and Gantry Crane Procedure

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7.5 7.6 8.0

Approved hand signals for overhead cranes. Written test of comprehension

REVISION HISTORY DATE Mar 1, 2011 MODIFICATIONS New

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